3D FEM Research Articles

Characterization of the dynamic forces transmitted to the support of a railway track, due to the roughness of wheels and rails - 3D finite element approach

Among the causes of railway vibrations, rail and wheel roughness is recognized as a major contribution. The excitation mechanism at work when rough wheels run on rough rails can be assimilated to a prescribed relative displacement between the wheels and the rails. This article deals with the modeling of this wheel/rail interaction phenomenon, using a 3D FEM approach. The input excitation data is the combined wheel / rail roughness spectrum, while the sought output is the spectrum of dynamic forces transmitted to the support. Characterization of these dynamic forces can be used, for instance, to assess the anti-vibration performance of a track. The presented approach overcomes the limitations of 2D or analytical approaches commonly encountered in dynamic studies of railway tracks: (a) It takes advantage of the finite element modeling flexibility, compared to analytical approaches, which are developed for specific configurations. (b) It can account for the infrastructure's dynamic flexibility, whether it is invariant in the longitudinal direction or not. (c) It can account for the 3D dynamic behavior of the track. As an illustration, the method is applied to a floating slab track, thereby showing the importance of the transverse modal behavior of the track in this case.

Microzonation Approach for Analyzing Regional Seismic Response: A Case Study of the Dune Deposit in Concón, Chile

Urban areas located on complex geological formations, such as dune deposits, require detailed seismic risk assessments that extend beyond standard seismic codes. This study focuses on the city of Concón, Chile, where a significant portion of the urban area is situated on a coastal dune deposit. The research integrates seismic microzonation with a three-dimensional finite element model (3D FEM) to comprehensively evaluate the regional seismic response. Field data from 208 strategically distributed points were collected and combined with geotechnical and geomorphological information to construct a detailed 3D model of the region. This model allowed for the simulation of seismic behavior under various conditions, highlighting the limitations of general seismic codes in capturing local variations in seismic response. The results underscore the importance of considering local geological conditions in structural design, particularly in areas with irregular topography and complex subsurface conditions. This study concludes that incorporating microzonation into urban planning and seismic analysis can significantly enhance infrastructure resilience and disaster preparedness, providing a replicable approach for other cities facing similar geological challenges.

Numerical investigation on loading pattern of railway concrete slabs

Despite the recent surge in the construction of ballastless railway tracks, there exists a notable research gap concerning the rail seat load (RSL) associated with these track types. The RSL is the load transferred from the rail to the fastening system, the plate beneath the rail and the rail pad. The prediction of RSL in ballasted track systems is widely investigated, however, there has been a relative lack of research into the ballastless railway track systems. In this paper, a 2D finite element model (2D FEM) was adopted to evaluate the RSL concerning the effective parameters, including sleeper spacing, fastening system stiffness and the flexural modulus of the rail. The numerical model was validated through a field test performed in the study. Moreover, a mathematical expression was proposed to determine the RSL ratio for concrete slab tracks. The RSL directly correlates with the sleeper spacing and the fastening stiffness, while this relation with the flexural rigidity is inverse. Based on the results, it was found that the RSL ratio obtained from the conventional methods differed considerably from the proposed mathematical expression. More specifically, this difference was observed in almost all of the values in the sleeper spacing and flexural rigidity of rail for the Kerr model except 0.68 m and 5 MN.m2, respectively.

Fast and accurate 3D FEM model for electromagnetic simulations of no-insulation HTS coils based on polygon-anisotropic-resistivity

Fast and accurate 3D FEM model for electromagnetic simulations of no-insulation HTS coils based on polygon-anisotropic-resistivity

Fast and accurate distal locking of interlocked intramedullary nails using computer-vision and a 3D printed device

IntroductionDistal locking is a challenging and time-consuming step in interlocked intramedullary nailing of long bone fractures. Current methods have limitations in terms of simplicity, universality, accuracy, speed, and safety. We propose a novel device and software for distal locking using computer vision.Methods and materialsThe device consists of an universal ancillary clamp, a telescopic arm, a viewfinder clamp, and a radio-opaque cross. The software uses a camera photo from the C-arm intensifier and adjusts for geometric projection deformities. The software employs edge detection, Hough transform, perspective interpolation, and vector calculation algorithms to locate the distal hole center. The device and software were designed, manufactured, and tested using 3D CAD, FEM, DRR, and performance testing on phantom bones.ResultsThe device and software showed high accuracy and precision of 98.7% and 99.2% respectively in locating the distal hole center and calculating the correctional vector. The device and software also showed high success ratio in drilling the hole and inserting the screw. The device and software reduced the radiation exposure for the surgeon and the patient. The success ratio of the device and software was validated by the physical testing, which simulated the real clinical scenario of distal locking. The radiation exposure was as low as 5 s with a radiation dose of 0.2mSv, drastically reducing radiation exposure during distal locking.DiscussionOur device and software have several advantages over other distal locking methods, such as simplicity, universality, accuracy, speed, and safety. Our device and software also have some disadvantages, such as reliability and legislation. Our device and software can be compared with other distal locking methods based on these criteria. Our device and software have some limitations and challenges that need to be addressed in the future, such as clinical validation, and regulatory approval.ConclusionThe device showed promising results in terms of low-cost, reusability, low radiation exposure, high accuracy, fast distal locking, high stiffness, and adaptability. The device has several advantages over other distal locking techniques, such as free-hand technique, mechanical aiming devices, electromagnetic navigation systems, and computer-assisted systems. We believe that our device and software have the potential to revolutionize the distal locking technique and to improve the outcomes and quality of life of the patients with long bone fractures.

Multidisciplinary design and manufacturing of a Tesla pump prototype

To widen the range of hydraulic efficiencies of boundary layer pumps, a full design methodology has been proposed in order to identify critical issues for their performance and manufacturing. The methodology integrated a 2D numerical code, CFD and FEM analyses, coupled with manufacturing assessments as feedback mechanism. Considering budget constraints and in-house machining capabilities, a quick first prototype was produced. Analyses of the design are pointing out that the volute design initially chosen will not help to achieve an increase in the overall efficiency. The curves of head achieved with 2D and CFD are in agreement, but the latter determines the losses with larger accuracy, thus achieving lower values of head. The 2D model shows limits in the determination of the efficiency, effectively corrected by the CFD analysis. Critical parameters as disc thickness and gap between discs will require a more sophisticated assembly process and materials outsource. The proposed methodology could be used as a reference for the design and performance evaluation of this kind of turbomachinery in the future. The procedure lead to a prototype design, whose optimal efficiency slightly lower than 30 % was achieved at 5000 rpm with 0.3 mm disks gap.

Susceptibility versus flexural stiffness in the stability of hybrid laminate columns with a rectangular cross section for a 1D model

Hybrid columns of FGM/FML type with inhomogeneous transverse structure perpendicular to their length are discussed. After that, laminated columns with different layups of laminate plies are discussed, with focus put on the effect exerted by many coupling of the stiffness submatrix on the lowest eigenvalue load. All columns were simply supported The study uses three methods for determining the lowest eigenvalues. The first two are analytical beam methods (i.e. 1D modelling approaches) based on the use of the Euler-Bernoulli theory. The proposed 1D methods are a generalisation of the well-known approach of determining the lowest eigenloads of isotropic columns. The first approach is to solve the eigenproblem directly from the differential equation of the deflection line. The second approach assumes that the curvature of the beam depends on the susceptibility of the beam. This is a fundamental assumption in the bending theory of beams and thin plates. The third method is the FEM (3D shell approach) which is used for the verification of the previous calculations. A comparison of the obtained results showed that the proposed 1D (one-dimensional) approach based on the full susceptibility matrix, which is the inverse stiffness matrix was as accurate as the 3D (three-dimensional) FEM shell model. The relative difference does not exceed 3%. Second 1D approach based on the stiffness matrix yields many times unacceptable differences relative to the reference results obtained by the FEM method. This comparison clearly demonstrates that an approach based on the assumption that curvature is directly proportional to susceptibility in flexural composite structures produces accurate results for all types of coupling.The existing literature extensively explores the impacts of stiffness matrix elements on both the linear and non-linear stability of laminate columns. However, there is a notable absence of studies focusing on the influence of susceptibility. This crucial aspect has been overlooked in prior studies. The present paper endeavors to fill this gap by shedding light on the influence of susceptibility, thereby emphasizing its significance in the analysis of laminate column stability.

Exact solutions for clamped spherical and cylindrical panels via a unified formulation and boundary discontinuous method

Numerous works in both recent and historical literature have concentrated on formulating theories to perform static analysis on simply-supported shell structures. However, it is worth noting that obtaining analytical solutions for clamped boundary conditions presents a strong challenge. In this paper, closed-form solutions for clamped cross-ply laminated and sandwich shells are achieved by employing a robust and hybrid methodology not previously reported in the literature. The high versatility of the Carrera Unified Formulation (CUF), based on the Equivalent-Single-Layer (ESL) description, is utilized to implement several refined shell theories. The Principle of Virtual Displacements (PVD) is utilized to derive the strong form of the governing equations in terms of displacement variables. As the main novelty, these equations are solved by the Boundary Discontinuous Fourier-based method (BDM) which provides highly accurate analytical solutions. The validity and robustness of the proposed methodology are assessed through a detailed comparison with references available in the open literature, as well as with FEM 3D results obtained with commercial software. Furthermore, the stress recovery technique is exploited to fulfill zero-stress and interlaminar continuity (IC) conditions. The findings might be useful in training artificial intelligence (AI) models, which, for instance, could facilitate the development of digital twin structures.

FINITE ELEMENT ANALYSIS OF CHANGING OF STRESS CONDITION CAUSED BY DIAMOND BURNISHING

The article is aspected to the finite element modelling of stress in subsurface layer of aluminium alloy workpiece during diamond burnishing process. This cold forming process is a simple, cost-effective finishing method that can be used to improve surface integrity and provide compressive residual stress. Available with these, durability and quality enhancement of the components can be reached, but improperly chosen burnishing parameters can distort the efficiency of the plastic deformation process. In order to optimize this, a 2D FEM model is created including the real surface integrity of the workpiece which was measured with AltiSurf 520 surface roughness measuring device. The method is simulated using DEFORM-2D software, corresponding to the numerical values of burnishing parameters implemented in practice as well, thereby allowing a comparative analysis with the results of X-ray diffraction measurement.

Non-polynomial zig-zag unified shear deformation formulation solved via boundary discontinuous method for laminated sandwich plates

Analytical solutions of mechanical problems with refined theories and challenge boundary conditions are still a topic of research due to intrinsic complexity. In this paper, a generalized refined theory is formulated to obtain analytical solutions for the static problem of cross-ply laminated and sandwich plates with several boundary conditions. These theories are implemented in the framework of the Carrera unified formulation (CUF) based on the equivalent-single-layer (ESL) approach. The displacement field of ESL-based models are expanded over the thickness direction by using non-polynomial terms, e.g. trigonometric, hyperbolic and the so-called zig-zag (ZZ) Murakami’s functions. The principle of virtual displacements (PVD) statement is used to derive the strong form of the governing equations in terms of displacements variables. These equations are solved by the boundary-discontinuous double Fourier series approach which provides highly accurate analytical solutions. This work gives a detailed comparison of results obtained using the presented ZZ models highlighting the differences with 3D FEM results. Furthermore, the influence of non-polynomial and ZZ terms in each ESL model is investigated. The superior robustness of the presented methodology compared to past works is demonstrated, making the proposed results suitable as a benchmark for validating new theories and finite elements. The findings can be also useful to train artificial intelligence (AI) models that can allow to the development of faster digital twin structure technology.

Transient thermal 2D FEM analysis of SiC MOSFET in short-circuit operation including high-temperature material laws and phase transition of aluminum source electrode

Understanding the electrothermal behavior of SiC MOSFET power devices under extreme operation conditions, such as short circuits, is crucial for their application certification. However, simulating short circuits in electronic components is challenging due to the necessity of a comprehensive thermal and electrical Multiphysics model that incorporates material laws and respects elevated temperatures with broad ranges. It is also needed to model the melting of the topside Al electrode. The paper presents for the first time a 2D electrothermal FEM that simulates the thermodynamic behavior of SiC MOSFET at high temperatures transistors under short-circuit conditions, including wide-range temperature-dependent material property laws. This work models the Al phase transition by considering the apparent heat capacity method and including the latent heat absorbed during the Al solid-liquid phase change (PC). The geometric accuracy of this study provides significant added values compared to existing 1D models. It was deduced that including the temperature-dependent material laws highly impacted the results. The rise in SiC junction temperature led to a delay in the onset of Al melting. It also impacted the progression manner of the Al melting process after the formation of new melting fronts.

CFT Connections: State-of-the-art Report and Numerical Validation by 3D FEM

Connections between concrete filled members are common in tall buildings, bridges, and offshore structures because of their robust structural performance. While extensive research has been done on isolated concrete-filled structural members, relatively little research has been conducted on composite connection regions. This article first describes a database on experimental/analytical investigations on concrete-filled connections comprising 135 tests. It then develops a generic numerical model capable of capturing the entire range of behavior of these connections, including local buckling of the steel tubes and friction/contact resistance between steel and concrete. The model was calibrated against a single test and its performance was verified against three other very different tests. The results indicate that the four models can track well the strength and stiffness of the specimens up to ultimate and predict well different failure patterns. Comparisons of the experimental and numerical load-deformation curves show very good agreement in predicting the strength and deformations at which different behaviors arise, and that performance is controlled primarily by both the strength of the concrete and the confinement effect of the steel tube in the connection area.

Investigation and selection of optimistic material for two wheeler brake disc: An experimental and finite element approach

The brake disc is a vital component in the braking system of the automobile which helps in reducing the speed or stopping the vehicle whenever required. Whereas, increasing the effectiveness of the braking system is highly challenging for the researchers to ensure safe driving by minimizing the stopping distance of the vehicle during braking. However, the performance of the braking system mainly relies on the brake disc material utilized in the braking system. In the current trend, the usage of alternate materials with a high strength-to-weight ratio is in practice to reduce the fuel consumption of the automobile. Hence, researchers concentrate on Fiber Reinforced Polymer Composites and Metal Matrix Composites to manufacture automotive components. In this research work, the performance of the existing mild steel brake rotor is correlated with brake discs fabricated using different materials such as zirconium-coated steel, AA7075+nSiCp, AA6061+nano Rice Husk Ash particles, Glass Fiber Reinforced Polymer composite, and Carbon Fiber Reinforced Polymer composites. The effectiveness of a two-wheeler braking system is reported concerning the stopping distance, disc weight, friction coefficient, and wear resistance properties of the brake disc material. Moreover, a 3D Finite Element Model (3D FEM) is also developed and the braking mechanism is simulated. The experimental and FEA results reveal that SiC reinforced AA7075 composite shows compromising properties as required such as maximum stress of 558 MPa, excellent wear resistance, good friction coefficient of 0.40, good temperature dissipation property, and effective stopping distance of 81 m.

Analysis of mechanical response and failure characteristics of tunnels crossing active faults considering axial force and geometrical nonlinearity

Tunnels subjected to active fault dislocation may experience significant damage. This paper establishes a novel methodology and solution procedure for analyzing the mechanical response and failure characteristics of tunnels subjected to active fault dislocation based on an elastic foundation beam model. The proposed methodology includes axial, transverse, and vertical soil-tunnel interaction terms, in addition to geometrical nonlinearity and axial force terms in the governing equation. This approach has a significantly extended application range, effectively addressing the problems encountered in tunnels crossing active faults with diverse crossing angles, dip angles, and fault types. The proposed methodology is verified by comparison to a 3D FEM model with various fault types, experimental tests, and on-site case, and the results are in excellent quantitative and qualitative agreement with the numerical, experimental, and on-site results. When fault displacement is below 0.5 m, disregarding geometric nonlinearity results in calculation errors of approximately 10% to 17% for peak axial force (Nmax), 18% to 22% for peak shear force (Vmax), and 20% to 30% for peak bending moment (Mmax). Finally, the responses caused by different factors, i.e., fault type, fault displacement, tunnel stiffness, and tunnel diameter, are investigated in detail to better understand tunnels crossing active faults. The results show that amongst the various fault types, the Vmax and the Mmax experienced by tunnels subjected to oblique slip-fault dislocation surpass those of other fault types, accompanied by the most extensive failure range. The augmentation of fault displacement, tunnel stiffness, and tunnel diameter precipitates a corresponding escalation in the Nmax, Vmax, Mmax, and failure range. Under oblique-slip fault dislocation, the tunnel undergoes an initial phase of shear failure, followed by tension-bending failure, delineated by distinct fault displacement thresholds of 0.1 m and 0.2 m, respectively. The proposed methodology provides the advantage of reliable stability analysis and design of tunnels crossing active faults.

A novel measurement‐protection‐integrated current transformer based on hybrid core and magnetic field sensor

AbstractCurrent transformers (CTs) are widely used for energy metering, relay protection, condition monitoring and control circuits. However, CT saturation may lead to non‐negligible measurement errors and relay malfunctions, posing a threat to the stability and security of the power grid. In order to address the problem of CT saturation, a novel measurement‐protection‐integrated current transformer (MPICT) is proposed. First, the working states of the MPICT are summarised and the approximate expressions for the steady‐state measuring characteristics, the transient response characteristics, and the measurement errors are derived from the equivalent circuit model. Then, the feasibility of the MPICT and the theoretical analyses are verified by the 3D FEM simulation imitating the presented MPICT excited by diverse currents. Finally, a down‐scale prototype is fabricated and a series of tests are conducted in the laboratory to validate the effectiveness of the equipment. The simulation and experimental results suggest that the output of the MPICT can accurately reconstruct the primary current waveform, even if the primary current contains decaying or constant DC component.

Unlocking high stability in perovskite solar cells through vacuum-deposited Cs3Bi2I9 thin layer

Perovskite solar cells (PSCs) show great potential for efficient solar energy conversion, but their long-term stability is still a concern. To address this issue, we developed a vacuum-deposited bismuth-based perovskite-like material (Cs3Bi2I9), which forms a high-quality thin film showing remarkable stability over 150 days of air exposure. When combined with a solution-processed MAPbI3 perovskite, the resulting device exhibits improved stability under varying environmental conditions. However, the power conversion efficiency (PCE) drops by 70% compared to the reference MAPbI3-based PSC. An advanced multiphysics optoelectrical device simulation combining 3D FDTD and FEM methods validates these findings, yielding results in excellent agreement with the experimental data. The study also provides insight into the device’s optics and electronic properties, revealing the factors that limit its performance. An optimized device design is proposed to reach an 18.81% PCE, higher than the reference device. The findings have significant implications for developing next-generation solar cells, including high-performance tandem solar cells.

Assessment of Building Response Supported on Shallow Foundation Due to Tunnelling in Cohesionless Soil

The depth of foundations significantly influences the building response due to tunnelling-induced ground movement. The present study investigates the responses caused by tunnelling on buildings supported on isolated footings. The response of buildings supported on shallow foundation systems due to progressive tunnelling is investigated through experimental and numerical methods. A three-dimensional finite element analysis (3D FEM) has been developed to evaluate the response of an existing reinforced cement concrete (RCC) building underpasses a circular-shaped tunnel in cohesionless soil. The model includes soil strata, footings, super-structure, and tunnel. Different parametric studies, i.e., C/D ratios, tunnel volume losses, and eccentricity of the building, have been considered in the present study. A scale-down model of the tunnel and building is prepared in the laboratory. The scale-down model simulates the volume loss during tunnelling and evaluates the response on surface and building components due to tunnelling. The surface settlement, total and differential settlement of the foundation, and induced strain on lining and building elementals are estimated. The numerical model is benchmarked with the experimental study conducted in the laboratory. It is observed that the numerical method agrees well with the experimental investigation. The responses of buildings supported on shallow footings are compared with available literature. The findings of the present study will be useful for the hazard estimation of existing buildings situated along/adjacent to a proposed alignment of the tunnel.

Estimation of landslide during heavy rainfall based on FEM-MPM model

In 2016, Typhoon No. 10 landed on Hokkaido, Japan and resulted in slope failures near Nissho Pass. The massive precipitation generated serious runoff within the catchment area, which accounted for the slope instability. Besides, the rainfall induced slope instability developed as landslide. However, the traditional slope instability analyses were often finished ignoring the transportation of instable soil. This study conducted soil runout analysis as well as slope instability analysis with a finite element method-material point method (FEM-MPM) model to catch the disaster area. In the slope instability analysis using three-dimensional (3D) FEM model, runoff and infiltration were considered at the same time to evaluate the slope instability during heavy rainfall. Here, the surface flow and subsurface flow were governed by shallow water equation, Richards’s equation and Green-Ampt infiltration capacity model. Then, based on the hydraulic field result, local factor of safety (LFS) distribution and dangerous spots were given by FEM model. Subsequently in the soil runout analysis using two-dimensional (2D) and 3D MPM model, large deformation part after failure and the soil transportation were examined to reveal the amount of soil that is risky to be washed away during heavy rainfall. The simulation results proved the appropriateness of this simulation method to reproduce the slope instability and landslide process during heavy rainfall.

Numerical modeling of blast-induced rock fragmentation in deep mining with 3D and 2D FEM method approaches

To optimize the excavation of rock using underground blasting techniques, a reliable and simplified approach for modeling rock fragmentation is desired. This paper presents a multistep experimental-numerical methodology for simplifying the three-dimensional (3D) to two-dimensional (2D) quasi-plane-strain problem and reducing computational costs by more than 100-fold. First, in situ tests were conducted involving single-hole and free-face blasting of a dolomite rock mass in a 1050-m-deep mine. The results were validated by laser scanning. The craters were then compared with four analytical models to calculate the radius of the crushing zone. Next, a full 3D model for single-hole blasting was prepared and validated by simulating the crack length and the radius of the crushing zone. Based on the stable crack propagation zones observed in the 3D model and experiments, a 2D model was prepared. The properties of the high explosive (HE) were slightly reduced to match the shape and number of radial cracks and crushing zone radius between the 3D and 2D models. The final methodology was used to reproduce various cut-hole blasting scenarios and observe the effects of residual cracks in the rock mass on further fragmentation. The presence of preexisting cracks was found to be crucial for fragmentation, particularly when the borehole was situated near a free rock face. Finally, an optimization study was performed to determine the possibility of losing rock continuity at different positions within the well in relation to the free rock face.

Comparative evaluation of effectiveness of three versus four mini-implants for simultaneous intrusion and retraction of maxillary anterior teeth: A 3D FEM study.

To evaluate and compare the displacement pattern of maxillary anterior teeth in the sagittal and vertical planes and evaluate the stress distribution in pdl, bone, teeth of the maxillary anterior region, and around the mini-implants during simultaneous en-masse retraction and intrusion using two, three, and four mini-implants combinations. A three-dimensional FEM model of maxillary teeth and periodontal ligament housed in the alveolar bone with extracted first premolarswasgenerated. The models were broadly divided into three groups according to the number of mini-implants. Mini-implants were placed bilaterally between the second premolar and molar in group I, and along with bilateral implants, an additional mid-implant was placed between the central incisors as in group II, whereas in group III, anterior mini-implants were placed in between lateral incisors and canine bilaterally. The two mini-implant model showed the maximum amount of retraction in the sagittal plane followed by three and four mini-implant models. In the vertical plane, all six anterior teeth showed intrusion only in the four mini-implant model. The stress in cortical bone, cancellous bone, PDL, around the mini-implants, and in lateral incisor was maximum in the three mini-implant model, followed by four mini-implants with the least stress in the two mini-implant model. The four mini-implant model is better than the three and two mini-implants model as there is a more even distribution of force in the four mini-implants model as compared to the three mini-implants model.